U.S. patent application number 16/675421 was filed with the patent office on 2020-05-28 for system and a method for producing a component.
This patent application is currently assigned to Airbus Operations GmbH. The applicant listed for this patent is Airbus Operations GmbH. Invention is credited to Matthias Hegenbart, Peter Linde.
Application Number | 20200164573 16/675421 |
Document ID | / |
Family ID | 70545476 |
Filed Date | 2020-05-28 |
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United States Patent
Application |
20200164573 |
Kind Code |
A1 |
Linde; Peter ; et
al. |
May 28, 2020 |
System And A Method For Producing A Component
Abstract
A system is proposed, using which a material is dispensed in a
web shape to additively produce a component. An in situ material
check is performed, wherein if a geometric deviation lying outside
a tolerance is established, material dispensing is interrupted to
carry out finish compacting of a dispensed material web by way of a
compacting unit.
Inventors: |
Linde; Peter; (Hamburg,
DE) ; Hegenbart; Matthias; (Hamburg, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Airbus Operations GmbH |
Hamburg |
|
DE |
|
|
Assignee: |
Airbus Operations GmbH
Hamburg
DE
|
Family ID: |
70545476 |
Appl. No.: |
16/675421 |
Filed: |
November 6, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 64/188 20170801;
B29C 64/118 20170801; B33Y 10/00 20141201; B29C 64/209 20170801;
B33Y 30/00 20141201 |
International
Class: |
B29C 64/188 20060101
B29C064/188 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 23, 2018 |
DE |
10 2018 129 559.6 |
Claims
1. A system for producing a component, comprising: a material
dispensing unit; a movement unit; a compacting unit having at least
one contact pressure surface; a material checking unit; and a
control unit, wherein the material dispensing unit is configured to
dispense a material supplied to the material dispensing unit in a
metered manner and in a web shape on a substrate, wherein the
movement unit is coupled to the material dispensing unit or the
substrate and is configured to carry out a relative movement
between the material dispensing unit and the substrate, so that the
material is dispensed on a predetermined path, wherein the material
checking unit is configured to examine the web-shaped dispensed
material for geometric deviations from a desired shape during or
immediately after the dispensing, and wherein the control unit is
coupled to the material dispensing unit, the movement unit, and the
material checking unit and is configured, upon detection of
geometric deviations of the web-shaped dispensed material, to
interrupt the dispensing of material by the material dispensing
unit and, on an already traversed path, to push the dispensed
material using the compacting unit into a desired web shape to
remedy the deviations.
2. The system according to claim 1, wherein the compacting unit is
configured to press the dispensed material continuously onto the
substrate immediately after the dispensing.
3. The system according to claim 1, wherein the compacting unit is
configured to be warmed at least at a contact point with the
dispensed material to remedy the deviations.
4. The system according to claim 1, wherein the compacting unit is
embodied as a carriage having a flat contact side comprising at
least one contact pressure surface configured to be pressed onto
the dispensed material.
5. The system according to claim 4, wherein the compacting unit has
a width exceeding a width of a dispensed material web.
6. The system according to claim 4 , wherein the at least one
contact pressure surface comprises a lateral contact pressure
surface parallel to a processing direction and perpendicular to the
substrate, and arranged on the contact side.
7. The system according to claim 1, wherein the compacting unit
comprises a cut-out protruding through the at least one contact
pressure surface, and wherein the material checking unit is mounted
in relation to the compacting unit in such a way that the material
checking unit examines a dispensed material web through the
cut-out.
8. The system according to claim 1, further comprising a protective
gas dispensing unit for the controlled generation of a protective
gas atmosphere in a material dispensing region.
9. The system according to claim 1, wherein the compacting unit,
the material checking unit, and the material dispensing unit are
jointly or at least partially mounted on one another.
10. The system according to claim 9, wherein the compacting unit,
the material checking unit, and the material dispensing unit are
jointly coupled to the movement unit.
11. The system according to claim 1, wherein the movement unit
comprises a robot arm.
12. The system according to claim 1, wherein the material
dispensing unit is configured to melt and dispense filaments made
of plastic.
13. The system according to claim 1, wherein the material checking
unit comprises an x-ray device.
14. A method for producing a component, comprising: executing a
relative movement between a material dispensing unit and a
substrate by a movement unit coupled to the material dispensing
unit or the substrate; metered web-shaped dispensing of a material
supplied to the material dispensing unit on the substrate on a
predetermined path by the material dispensing unit; during or
immediately after the dispensing, examining the web-shaped
dispensed material for geometric deviations from a desired shape by
a material checking unit; and upon detection of geometric
deviations of the web-shaped dispensed material, interrupting the
dispensing of material and remedying the deviations on an already
traversed path by pushing the dispensed material using a compacting
unit into the desired web shape.
Description
FIELD OF THE INVENTION
[0001] The system relates to a system and a method for producing a
component.
BACKGROUND OF THE INVENTION
[0002] Numerous different systems and methods exist for producing
components. The following embodiments relate in particular to
systems and methods for the additive and/or generative production
of components.
[0003] Producing a component by successive web-shaped dispensing of
material onto a substrate is known. For this purpose, a material
dispensing unit is provided, which can dispense material in a
metered manner onto a substrate. To achieve a desired component
geometry, a relative movement is typically provided between the
substrate and the material dispensing unit. Using a thermoplastic
in particular for this purpose is known, which is supplied to the
material dispensing unit as a filament and is heated therein to be
dispensed onto the substrate.
[0004] It is to be observed that in such a procedure, the tensile
strength of the component in the web direction, i.e., along the
extension of the dispensed filaments, is higher than transversely
thereto. It can often be established by component checking, which
is executable destructively or by imaging methods, that sometimes
air inclusions or incomplete adhesions can occur between the
individual material webs.
BRIEF SUMMARY OF THE INVENTION
[0005] It would be desirable to be able to preclude such
inconsistencies from the outset to obtain a component having
defined mechanical properties. Aspects of the invention may propose
a system and/or method for producing a component, using which
precise additive production of a component can be implemented,
which has reliable and reproducible desired mechanical
properties.
[0006] A system for producing a component is proposed, the system
comprising a material dispensing unit, a movement unit, a
compacting unit, a material checking unit, and a control unit,
wherein the material dispensing unit is designed to dispense a
material supplied to the material dispensing unit in a metered
manner and in a web shape on a substrate, wherein the movement unit
is coupled to the material dispensing unit or the substrate and is
designed to carry out a relative movement between the material
dispensing unit and the substrate, so that the material is
dispensed on a predetermined path, wherein the material checking
unit is designed to examine the web-shaped dispensed material for
geometric deviations from a desired shape during or immediately
after the dispensing, and wherein the control unit is coupled to
the material dispensing unit, the movement unit, and the material
checking unit and is designed, upon detection of geometric
deviations of the web-shaped dispensed material, to interrupt the
dispensing of material by the material dispensing unit and, on an
already traversed path, to push the dispensed material using the
compacting unit into a desired web shape to remedy the
deviations.
[0007] The material dispensing unit can be coupled to a material
store, which provides the material to be dispensed. The material
dispensing unit can have a conveying capacity for conveying the
material from the material store to a dispensing opening. In
addition, a heating device can be provided for heating and in
particular for melting the supplied material. Depending on the
material used, the material dispensing unit can also be constructed
differently. In the following description, the material dispensing
unit is provided to dispense the material in a metered and
web-shaped manner onto a substrate, independently of the technology
used. The heating can be carried out by an electrical resistance
heating device and/or with the aid of radiation by visible or
non-visible light or electromagnetic radiation in general. The type
and embodiment of the heating device can be dependent on the
material used, which comprises, in addition to all meltable and
weldable plastics, also metallic or other weldable materials. It
would be conceivable, for example, to dispense the material to be
dispensed in the form of filaments, which are heated and melted by
a laser.
[0008] As explained at the outset, the movement unit is provided to
achieve a relative movement between the material dispensing unit
and the substrate. The goal of the additive manufacturing of a
component is the successive application of material in a desired
form. A predetermined path can be followed by the relative
movement, wherein this path is provided with material by single or
multiple coating. The movement unit could in particular be designed
to execute a three-dimensional relative movement. Thus, a movement
can take place not only in one plane, but rather also
perpendicularly to this plane. The movement unit does not
necessarily have to be a single separate movement unit, but rather
it could also be implemented as a combination of multiple movement
devices. For example, a first movement device could be provided for
generating a planar relative movement, while a second movement
device carries out a movement perpendicularly thereto. The latter
movement could be achieved, for example, by a vertically adjustable
base.
[0009] One particular advantage of the system according to an
embodiment of the invention is the use of a material checking unit,
which examines the material web for geometric deviations during the
dispensing or immediately after the dispensing of the material. The
material checking unit is therefore provided for in situ material
checking.
[0010] The technology of the material checking unit can, however,
be selected in dependence on the material used. Numerous different
sensors and methods exist for performing a material check. Using
optical or acoustic devices can suggest itself. In the case of an
optical device, an optical scanning of the material web could be
performed to subsequently analyse the items of image information
and derive inferences about possible flaws therefrom. However, this
is more suitable for lateral, directly visible gaps between
adjacent material webs. Flaws concealed by the material web would
then remain undiscovered. Therefore, this type of the examination
could be restricted more to a small number of types of
material.
[0011] Using an ultrasonic measuring device could also suggest
itself, which conducts an ultrasonic signal into the material web
and adjacent regions and studies the sound waves radiated back into
the ultrasonic measuring device. In this way, in particular
boundary surfaces below the surface can be detected, which are to
be attributed, for example, to air inclusions and directly reflect
the ultrasound depending on the alignment of the boundary surface.
Such a discrete, reflected signal could therefore be interpreted as
an inclusion.
[0012] Furthermore, the material checking unit can be based on
devices of diagnostic radiology and in particular can comprise a
computer tomograph. Very well resolved items of image information
can be provided thereby, which are also three-dimensional if
needed. It can thus be immediately recognized whether a
discontinuity exists due to a dispensed material web on the
component to be produced.
[0013] The analysis of the items of information supplied by the
material checking unit can be effectuated using the control unit or
a computer unit connected thereto. The control unit is a device
which is coupled to the above-mentioned main components. The
control unit can therefore control the entire procedure of the
production of the component. In addition to the activation of the
material dispensing unit and the movement unit, the control unit
can receive in situ items of information about the quality of the
dispensed material web from the material checking unit, perform an
analysis immediately in the meantime, and thereupon influence the
procedure of the production of the component.
[0014] The control unit is therefore capable of checking a material
web and/or a presently processed region of the component for
geometric deviations. A completely flawless execution is not
absolutely necessary and is possibly also not implementable. The
control unit should therefore be designed to execute the
examination in consideration of a certain error tolerance. If
discontinuities are detected, they could be expressed by a defined
numeric value in dependence on the size of the discontinuity, which
is compared to a predetermined tolerance. If this tolerance is then
exceeded, the control unit can effectuate the stopping of the
construction and effectuate postprocessing of the dispensed
material.
[0015] The compacting unit can represent a unit which can be
brought into contact with the dispensed material. By exerting a
mechanical pressure in the direction of the substrate or in the
direction of prior webs, with which the present web has to be
connected, the material web inducing a discontinuity can be brought
into shape. The particular advantage is that the material checking
unit can already establish during the postprocessing or immediately
thereafter whether the previously detected discontinuity has
already been sufficiently remedied.
[0016] In summary, the system according to an embodiment of the
invention is capable of producing a component which reliably and
reproducibly has previously determined mechanical properties, since
even ultra small inconsistencies can be detected and remedied if
necessary immediately during the production procedure.
[0017] In one advantageous embodiment, the compacting unit is
designed to press the dispensed material continuously onto the
substrate immediately after the dispensing. The probability that a
flaw will occur during the application of material can thus already
be reduced.
[0018] The compacting unit is preferably designed to be warmed at
least at a contact point with the dispensed material to remedy the
deviations. During the dispensing of plastic, in this way, for
example, local melting or softening of the material could be
achieved. After the pressing on, the material can adhere
accordingly to the prior material webs or to the substrate,
respectively. The warming or heating can also be carried out in
general at this point by an electrical resistance heating device
and/or with the aid of radiation by visible or non-visible light or
electromagnetic radiation. The type and embodiment of the heating
device can be dependent on the material used.
[0019] In one advantageous embodiment, the compacting unit is
embodied as a carriage, which comprises a flat contact side, which
can be pressed onto the dispensed material. Such a carriage can be
coupled in a simple manner, for example, to the material dispensing
unit, so that during a relative movement carried out between the
substrate and the material dispensing unit, the carriage is always
placed at the same location in relation to the material dispensing
unit. A carriage can additionally be displaced very easily on a
dispensed material, which can also be improved, for example, by a
curved tip or front edge. The compacting unit can in this manner
already compact material on the substrate during the procedure of
dispensing thereof and therefore improve the adhesion already at
the beginning.
[0020] The carriage preferably has a width which exceeds the width
of a dispensed material web. The dispensed material web is
therefore not only pressed locally and separately in the direction
of the substrate, but rather the carriage can overlap a seam to at
least one adjacent material web, so that in this way extensive
equalizing of material web heights is carried out. The material is
then generally speaking pushed more toward the adjacent material
web at least at the seam.
[0021] The at least one contact pressure surface could comprise a
lateral contact pressure surface, which is parallel to a processing
direction and perpendicular to the substrate, and which is arranged
on the contact side. The lateral, perpendicularly extending contact
pressure surface permits the delimitation of a possible elongation
movement of the web-shaped dispensed material. The lateral contact
pressure surface can in particular delimit a free lateral side of
the just dispensed material web. Therefore, guiding the at least
one contact pressure surface in the movement sequence behind the
material dispensing device suggests itself, so that immediately
after the application of the material, it is kept in shape by the
at least one contact pressure surface.
[0022] The compacting unit can comprise a cut-out protruding
through the at least one contact pressure surface, wherein the
material checking unit is mounted in relation to the compacting
unit in such a way that the material checking unit examines a
dispensed material web through the cut-out. Therefore, immediately
after the material is pressed onto the substrate, its geometric
properties can be examined The cut-out is to be positioned so that
pressing on of the dispensed material is possible and the
examination can take place as much as possible immediately after
the depositing and the pressing on of the material.
[0023] In one particularly advantageous embodiment, the system
furthermore comprises a protective gas dispensing unit for the
controlled generation of a protective gas atmosphere in a material
dispensing region. This can be advantageous in particular upon the
use of an extrusion device and a plastic material in filament form.
The plastic material exiting from the extrusion device then enters
a protective gas atmosphere, which improves an adhesion of the
individual material webs and can therefore significantly improve
the mechanical properties. The protective gas could be nitrogen or
argon, for example.
[0024] The compacting unit, the material checking unit, and the
material dispensing unit are particularly preferably mounted
jointly or at least partially one on another. The construction of
the system is facilitated and the three main components are
coherent geometrically and/or in the position thereof.
[0025] The compacting unit, the material checking unit, and the
material dispensing unit are preferably coupled jointly to the
movement unit. The three components can thus be moved over the
substrate using the movement unit. Providing a common mounting
frame, which is coupled to the movement unit, suggests itself for
this purpose.
[0026] The movement unit could in particular comprise a robot arm.
Three-dimensional guiding of at least the material dispensing unit
can thus be performed. Furthermore, the possibility is also
provided of providing more than only three degrees of freedom, but
rather also four, five, or six degrees of freedom, which result by
rotation around one, two, or three spatial axes. More complex,
three-dimensionally curved, planar components can thus also be
produced, in which the individual material webs extend curved in
space. This could be possible, for example, upon the use of a
curved substrate.
[0027] The material dispensing unit could be designed to melt and
dispense filaments made of plastic. For this purpose, the material
dispensing unit can comprise an extrusion device, through which the
heated plastic material exits, wherein the dispensed material web
has a precise cross section predetermined by the extrusion
device.
[0028] The material checking unit particularly preferably comprises
an x-ray device. Concealed geometric deviations can thus also be
detected easily.
[0029] The invention furthermore relates to a method for producing
a component. The method comprises the steps of executing a relative
movement between a material dispensing unit and a substrate by
means of a movement unit, which is coupled to the material
dispensing unit or the substrate, the metered web-shaped dispensing
of a material supplied to the material dispensing unit on the
substrate on a predetermined path by means of the material
dispensing unit, examining the web-shaped dispensed material for
geometric deviations from a desired shape by means of a material
checking unit during or immediately after the dispensing, and upon
detection of geometric deviations of the web-shaped dispensed
material, interrupting the dispensing of material and remedying the
deviations on an already traversed web by pushing the dispensed
material using a compacting unit into a desired web shape.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Further features, advantages, and possible applications of
the present invention result from the following description of the
exemplary embodiments and the figures. In this case, all features
which are described and/or illustrated form the subject matter of
the invention as such and in any arbitrary combination, even
independently of the combination thereof in the individual claims
or the references thereof. In the figures, identical reference
signs furthermore stand for identical or similar objects.
[0031] FIG. 1 shows a system according to the invention in a
three-dimensional view.
[0032] FIGS. 2a and 2b show details of a compacting unit.
[0033] FIGS. 3a and 3b respectively show the procedure of
dispensing and finish compacting in a top view and a side view in
each case of the compacting unit.
[0034] FIG. 4 shows the method according to the invention in a
schematic block diagram.
DETAILED DESCRIPTION
[0035] FIG. 1 shows a system 2 for producing a component 4 in a
schematic, three-dimensional view. The system 2 comprises a
material dispensing unit 6, a movement unit 8, a compacting unit
10, and a material checking unit 12. In the illustrated case, the
material dispensing unit 6 comprises a heating device 14, to which
a plastic in the form of a filament 16 can be applied via a
material intake 18. In the heating device 14, the filament 16 is
heated and melted for this purpose. The molten material is
subsequently dispensed to the outside through an extrusion nozzle
20 as an extrusion device.
[0036] The filament 16 is kept ready on a coil 22. The material
dispensing unit 6 can comprise a corresponding conveyor device for
conveying the filament 16. The coil 22 can be rotatably mounted
around an axis 24. It is not necessary for the coil 22 to be
located in the immediate vicinity of the material dispensing unit
6, as long as an interference-free supply of the filament 16 to the
material dispensing unit 6 is possible.
[0037] The movement unit 8 is embodied in this exemplary embodiment
as a robot arm. It comprises multiple arm elements 26, which are
movable in relation to one another. The movement unit 8 is
particularly preferably designed to carry out a complete
three-dimensional movement. The material dispensing unit 6 can
therefore be moved to arbitrary three-dimensional positions in
space, in dependence on the mechanical action radius of the
movement unit 8. It is provided by way of example here that the
movement unit 8 is directly connected to the material dispensing
unit 6.
[0038] The component 4 is formed on a substrate 28 or a base 28 by
web-shaped dispensing of the material 16. FIG. 1 shows how material
leaves the extrusion nozzle 20 and is added as a material web 30 to
already existing material webs 32. By moving the material
dispensing unit 6, material webs 30 can therefore be dispensed
adjacent to one another and one on top of another to successively
form the component 4.
[0039] The compacting unit 10 is embodied by way of example as a
carriage, which has a flat contact side 34. A first contact
pressure surface 36 is provided thereon. The first contact pressure
surface 36 is pressed onto the just dispensed material web 30 and
guided after the material dispensing unit 6. A flush application of
the material web 30 in relation to the already existing material
webs 32 can thus be assisted. In the example shown, the compacting
unit 10 has a width b which exceeds the width of the material web
30. A seam 38 can thus be overlapped, so that finally the just
dispensed material web 30 is aligned vertically flush with the
adjacent material webs 32.
[0040] The compacting unit 10 is arranged on a mounting frame 40,
which is connected to the material dispensing unit 6. The
compacting unit 10 thus always follows the movement of the material
dispensing unit 6. In addition, the material checking unit 12,
which checks the just dispensed material web 30 for possible
geometric deviations from a desired path, is arranged on the
mounting frame 40. For this purpose, the compacting unit 10
comprises a cut-out 42, which protrudes through the first contact
pressure surface 36. The material checking unit 12 is aligned in
such a way that a check can be carried out through the cut-out 42.
A viewing axis from the material checking unit 12 is therefore to
be oriented undisturbed by the cut-out 42 on the material web 30
being dispensed.
[0041] In the example shown, the material checking unit 12
comprises an x-ray source 44, which emits a bundled or fanned-out
x-ray in the direction of the cut-out 42. The base 28 could be
equipped with a detector, by which the x-rays passing through the
component 4 are detectable. By arranging the material checking unit
12 at a fixed distance in relation to the material dispensing unit
6, the dispensed material web 30 is always checked in situ for
possible flaws or geometric deviations.
[0042] A control unit 46 is connected to the material checking unit
12 and the material dispensing unit 6 and the movement unit 8. The
control unit 46 can control the procedure of the production of the
component 4 in that the movement unit 8 is activated to carry out a
movement of the material dispensing unit 6 along predetermined
paths and simultaneously to check the dispensed material web 30.
The material checking unit 12 supplies data for this purpose to the
control unit 46, which represent the state of the material web 30.
The control unit 46 can be designed for the purpose of receiving
raw data, interpreting them independently on the basis of an
algorithm, and comparing them in the scope of a predetermined,
adjustable tolerance to predetermined geometric properties or state
variables. The control unit 46 could also be connected to a further
unit (not shown here), however, which generates comparable state
data from the raw data of the material checking unit 12. This unit
could also be integrated into the material checking unit 12.
[0043] If the control unit 46 should detect a geometric deviation
outside the set tolerance, the control unit 46 can be designed to
interrupt the dispensing procedure by the material dispensing unit
6. The movement unit 8 could then be activated so that an opposing
movement is performed and the compacting unit 10 could push the
dispensed material web 30 into its desired shape. For this purpose,
the compacting unit 10 is provided with a heating device 48, which
is supplied with electrical voltage via a power supply 50, such as
a current source. The heating device 48 is also coupled to the
control unit 46 to be activated or deactivated as needed. Local
softening of the dispensed material web 30 can take place due to
heating of the first contact pressure surface 36 and the material
can be pressed into shape by moving the compacting unit 10. The
success of this procedure can be checked simultaneously by the
material checking unit 12. The control unit 46 is preferably
designed so that this finish compacting is carried out until the
established geometric deviations disappear or are within the
tolerance. A user can monitor the entire procedure via a monitoring
unit 51, which is shown here on the basis of a monitor.
[0044] FIG. 1 furthermore shows a protective gas dispensing unit 53
having a protective gas storage tank 52, which dispenses a
protective gas into a nozzle 56 via a gas line 54 and at the same
time forms a protective gas atmosphere around the extrusion device
20. The adhesion of the molten plastic material on already
dispensed material webs 32 can thus be improved. Alternatively,
instead of a protective gas storage tank 52, a gas storage tank 52
which contains a combustible gas can also be provided. This could
be supplied to the material dispensing unit 6 to heat the filament
16.
[0045] A switching unit 58, which is coupled via lines 60 to the
control unit 46, is shown solely by way of example. Using this, the
control unit 46 is capable of performing switching procedures to
the material dispensing unit 6 and the heating device 48 so that
the dispensing of material and the heating of the compacting unit
10 can be activated or deactivated as needed.
[0046] FIGS. 2a and 2b show the compacting unit 10 in somewhat more
detailed illustrations. The heating device 48 can be seen as
meandering heating spirals on an upper side 62. These are supplied
with electrical voltage as needed via a supply line 64. A front
side 66 oriented toward the material dispensing unit 6 has a slight
curvature, so that the compacting unit 10 can slide easily on the
dispensed material web 32. Moreover, the front side 66 is prevented
from tilting with the dispensed material web 32. The cut-out 42,
which is enclosed completely by the heating device 48, is located
behind the mounting frame 40.
[0047] A stud 68, which is aligned perpendicularly to the first
contact pressure surface 36 and comprises a second contact pressure
surface 70, extends on the contact side 34. This stud is aligned
laterally and can slide along a lateral delimitation 72 (see FIG.
1) of the just dispensed material web 30.
[0048] The first contact pressure surface 36 and the second contact
pressure surface 70 are each equipped with friction devices 74,
which push the material of the dispensed material web 30 in reverse
along the filament extension during a movement of the compacting
unit 10 in a reverse direction due to a somewhat strengthened
friction, so that a certain finish contacting is thus also
achieved. The friction devices 74 can be embodied as points having
elevated roughness or as edges oriented in the reverse
direction.
[0049] In FIGS. 3a and 3b, respectively the dispensing (FIG. 3a)
and the finish compacting (FIG. 3b) are each shown in the two views
(top view and side view). FIG. 3a shows the compacting unit 10 in a
top view, wherein it can be established through the cut-out 42 that
a deviation 76 is present in the form of a flaw, i.e., in
particular an incomplete adhesion. This can be recognized by the
material checking unit 12 immediately after the application of the
material web 30. As indicated, a switch 78 for activating the
heating device 48 is open, i.e., the compacting unit 10 only
travels directly over the just dispensed material 30 during the
dispensing of the material and permits the checking of the material
web 30 through the cut-out 42.
[0050] Due to establishing the geometric deviation, which is
outside a tolerance, for example, the switch 78 is closed, so that
the heating device 48 is activated. This is shown in FIG. 3b. The
compacting unit 10 is then moved in the opposite direction, so that
finish compacting is carried out. This is also checked in situ by
the material checking unit 12. If the finish compacting has
proceeded so that all geometric deviations are remedied, the
dispensing of the material web 30 can be continued.
[0051] FIG. 4 shows a block diagram to illustrate the method. The
method comprises the steps of executing 80 a relative movement
between the material dispensing unit 6 and the substrate 28 by
means of the movement unit 8, which is coupled to the material
dispensing unit 8 or the substrate 28. Simultaneously, a material
supplied to the material dispensing unit 6 is dispensed 82 in a
metered manner and in a web shape on the substrate 28 on a
predetermined path by means of the material dispensing unit 6.
During or immediately after the dispensing 82, the web-shaped
dispensed material is checked 84 for geometric deviations from a
desired shape by means of the material checking unit 12. If
geometric deviations of the web-shaped dispensed material are
detected, the dispensing of material is interrupted 86 and the
deviations on an already traversed path are remedied 88 by pushing
the dispensed material using the compacting unit 10 into a desired
web shape.
[0052] In addition, it is to be noted that "comprising" does not
exclude other elements or steps and "a" or "one" does not exclude a
plurality. Furthermore, it is to be noted that features which have
been described with reference to one of the above exemplary
embodiments can also be used in combination with other features of
other above-described exemplary embodiments. Reference signs in the
claims are not to be considered to be a restriction.
[0053] While at least one exemplary embodiment of the present
invention(s) is disclosed herein, it should be understood that
modifications, substitutions and alternatives may be apparent to
one of ordinary skill in the art and can be made without departing
from the scope of this disclosure. This disclosure is intended to
cover any adaptations or variations of the exemplary embodiment(s).
In addition, in this disclosure, the terms "comprise" or
"comprising" do not exclude other elements or steps, the terms "a"
or "one" do not exclude a plural number, and the term "or" means
either or both. Furthermore, characteristics or steps which have
been described may also be used in combination with other
characteristics or steps and in any order unless the disclosure or
context suggests otherwise. This disclosure hereby incorporates by
reference the complete disclosure of any patent or application from
which it claims benefit or priority.
LIST OF REFERENCE SIGNS
[0054] 2 system [0055] 4 component [0056] 6 material dispensing
unit [0057] 8 movement unit/robot arm [0058] 10 compacting unit
[0059] 12 material checking unit [0060] 14 heating device [0061] 16
filament/material [0062] 18 material intake [0063] 20 extrusion
device/extrusion nozzle [0064] 22 coil [0065] 24 axis [0066] 26 arm
element [0067] 28 substrate/base [0068] 30 material web (being
dispensed) [0069] 32 material web (existing) [0070] 34 contact side
[0071] 36 first contact pressure surface [0072] 38 seam [0073] 40
mounting frame [0074] 42 cut-out [0075] 44 x-ray source [0076] 46
control unit [0077] 48 heating device [0078] 50 power supply [0079]
51 monitoring unit [0080] 52 protective gas storage tank [0081] 53
protective gas dispensing unit [0082] 54 gas line [0083] 56 nozzle
[0084] 58 switching unit [0085] 60 line [0086] 62 upper side [0087]
64 supply line [0088] 66 front side [0089] 68 stud [0090] 70 second
contact pressure surface [0091] 72 lateral delimitation [0092] 74
friction device [0093] 76 deviation [0094] 78 switch [0095] 80
moving [0096] 82 dispensing [0097] 84 checking/examining [0098] 86
interrupting [0099] 88 remedying
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